Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU WD600-3 SHOP MANUAL SEBM022908 – PDF DOWNLOAD
$34.95
KOMATSU WD600-3 SHOP MANUAL SEBM022908 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU WD600-3 SHOP MANUAL SEBM022908 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WD600-3 SHOP MANUAL SEBM022908 – PDF DOWNLOAD
Language : English
Pages : 928
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WD600-3 SHOP MANUAL SEBM022908 – PDF DOWNLOAD
COVER................................................................................................................................................................. 1 CONTENTS.............................................................................................................................................................. 2 List of revised pages................................................................................................................................................. 3 SAFETY................................................................................................................................................................ 7 SAFETY NOTICE..................................................................................................................................................... 7 FOREWORD.............................................................................................................................................................. 9 GENERAL........................................................................................................................................................... 9 HOW TO READ THE SHOP MANUAL....................................................................................................................................... 10 HOISTING INSTRUCTIONS............................................................................................................................................. 11 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER........................................................................................................ 12 COATING MATERIALS................................................................................................................................................. 14 STANDARD TIGHTENING TORQUE........................................................................................................................................ 16 ELECTRIC WIRE CODE................................................................................................................................................ 19 CONVERSION TABLE.................................................................................................................................................. 20 UNITS............................................................................................................................................................. 26 01 GENERAL............................................................................................................................................................ 27 GENERAL ASSEMBLY DRAWING.......................................................................................................................................... 28 SPECIFICATIONS.................................................................................................................................................... 29 WEIGHT TABLE...................................................................................................................................................... 32 LIST OF LUBRICANT AND WATER....................................................................................................................................... 33 10 STRUCTURE AND FUNCTION............................................................................................................................................. 35 COOLING SYSTEM.................................................................................................................................................... 36 GENERAL........................................................................................................................................................... 38 POWER TRAIN SYSTEM................................................................................................................................................ 40 TORQUE CONVERTER AND TRANSMISSION PIPING.......................................................................................................................... 42 TORQUE CONVERTER.................................................................................................................................................. 44 TORQUE CONVERTER REGULATOR VALVE.................................................................................................................................. 48 LOCK-UP VALVE..................................................................................................................................................... 50 LOCK-UP SOLENOID VALVE............................................................................................................................................ 54 TORQUE CONVERTER RELIEF VALVE..................................................................................................................................... 55 TRANSMISSION...................................................................................................................................................... 57 TRANSMISSION CONTROL VALVE........................................................................................................................................ 62 LUBRICATION BYPASS VALVE.......................................................................................................................................... 72 TRANSMISSION SOLENOID VALVE....................................................................................................................................... 73 EMERGENCY MANUAL SPOOL............................................................................................................................................ 75 TRANSFER.......................................................................................................................................................... 76 DRIVE SHAFT....................................................................................................................................................... 77 CENTER SUPPORT.................................................................................................................................................... 78 AXLE.............................................................................................................................................................. 79 DIFFERENTIAL...................................................................................................................................................... 81 FINAL DRIVE....................................................................................................................................................... 89 AXLE AND CENTER HINGE PIN......................................................................................................................................... 90 STEERING PIPING................................................................................................................................................... 92 STEERING COLUMN................................................................................................................................................... 94 STEERING UNIT (ORBIT-ROLL VALVE).................................................................................................................................. 95 STEERING VALVE.................................................................................................................................................... 98 TWO-WAY RESTRICTION VALVE.........................................................................................................................................109 STOP VALVE........................................................................................................................................................110 EMERGENCY STEERING PIPING.........................................................................................................................................111 DIVERTER VALVE (for emergency steering)...........................................................................................................................112 BRAKE PIPING......................................................................................................................................................115 BRAKE VALVE.......................................................................................................................................................116 CHARGE VALVE......................................................................................................................................................121 ACCUMULATOR (FOR BRAKE)...........................................................................................................................................125 SLACK ADJUSTER....................................................................................................................................................126 BRAKE.............................................................................................................................................................129 PARKING BRAKE.....................................................................................................................................................131 SPRING CYLINDER...................................................................................................................................................133 PARKING BRAKE SOLENOID VALVE......................................................................................................................................134 HYDRAULIC PIPING..................................................................................................................................................135 WORK EQUIPMENT LEVER LINKAGE......................................................................................................................................136 HYDRAULIC TANK....................................................................................................................................................137 ACCUMULATOR (FOR PPC VALVE).......................................................................................................................................140 PPC VALVE.........................................................................................................................................................141 PPC RELIEF VALVE..................................................................................................................................................146 WORK EQUIPMENT VALVE..............................................................................................................................................148 DECO VALVE........................................................................................................................................................159 AIR CONDITIONER...................................................................................................................................................170 MACHINE MONITOR SYSTEM............................................................................................................................................173 MAIN MONITOR......................................................................................................................................................174 MAINTENANCE MONITOR...............................................................................................................................................178 ENGINE STARTING CIRCUIT...........................................................................................................................................180 ENGINE STOP CIRCUIT...............................................................................................................................................181 BATTERY DISCONNECT SWITCH CIRCUIT (If equipped)...................................................................................................................182 PRE-HEATING CIRCUIT...............................................................................................................................................184 ELECTRIC TRANSMISSION CONTROL.....................................................................................................................................185 KICK-DOWN, HOLD SWITCH............................................................................................................................................188 TRANSMISSION AND JOYSTICK STEERING SYSTEM.........................................................................................................................189 THROTTLE CONTROL SYSTEM...........................................................................................................................................208 20 TESTING AND ADJUSTING..............................................................................................................................................215 STANDARD VALUE TABLE..............................................................................................................................................216 STANDARD VALUE TABLE FOR ENGINE...............................................................................................................................216 STANDARD VALUE TABLE FOR CHASSIS..............................................................................................................................217 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.....................................................................................................................223 TESTING AND ADJUSTING.............................................................................................................................................235 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....................................................................................................236 MEASURING ENGINE SPEED........................................................................................................................................238 MEASURING EXHAUST GAS COLOR...................................................................................................................................240 ADJUSTING VALVE CLEARANCE.....................................................................................................................................241 TESTING AND ADJUSTING INJECTOR LIFT...........................................................................................................................242 MEASURING COMPRESSION PRESSURE................................................................................................................................244 MEASURING BLOW-BY PRESSURE....................................................................................................................................246 MEASURING ENGINE OIL PRESSURE.................................................................................................................................247 REPLACING FAN BELT ADJUSTING AUTO-TENSIONER...................................................................................................................248 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.................................................................................................................249 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.............................................................................................250 HANDLING EQUIPMENT IN FUEL CIRCUIT............................................................................................................................251 MEASURING FUEL PUMP OUTLET PORT PRESSURE......................................................................................................................251 BLEEDING AIR FROM FUEL CIRCUIT................................................................................................................................252 MEASURING EXHAUST TEMPERATURE (OVERALL ENGINE)................................................................................................................254 MEASURING EXHAUST GAS TEMPERATURE (EACH CYLINDER).............................................................................................................255 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)................................................................................................................256 ADJUSTING SPEED SENSOR........................................................................................................................................257 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION...................................................................................................258 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL................................................................................................................261 TESTING AND ADJUSTING STEERING OIL PRESSURE...................................................................................................................263 TESTING AND ADJUSTING STEERING STOP VALVE.....................................................................................................................265 TESTING BRAKE OIL PRESSURE....................................................................................................................................266 MEASURING WEAR OF BRAKE DISC..................................................................................................................................267 MEASURING BRAKE PERFORMANCE...................................................................................................................................268 TESTING AND ADJUSTING PARKING BRAKE...........................................................................................................................269 TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE..........................................................................................271 TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS.........................................................272 TESTING AND ADJUSTING PPC OIL PRESSURE........................................................................................................................284 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.......................................................................................................286 ADJUSTING WORK EQUIPMENT LEVER LINKAGE........................................................................................................................287 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)...................................................................................................................289 BLEEDING AIR..................................................................................................................................................290 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.............................................................................................................291 Pm CLINIC INSPECTION TABLE....................................................................................................................................292 TROUBLESHOOTING...................................................................................................................................................295 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................................................296 SEQUENCE OF EVENTS IN TROUBLESHOOTING.........................................................................................................................297 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..............................................................................................................298 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................................306 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................................................................................307 CONNECTOR ARRANGEMENT DIAGRAM.................................................................................................................................312 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................................................316 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................................333 METHOD OF USING MATRIX TROUBLESHOOTHING TABLES................................................................................................................335 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....................................................................................................................337 METHOD OF USING TROUBLESHOOTING CHART.....................................................................................................................338 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).............................................................................................342 S-2 ENGINE DOES NOT START.................................................................................................................................344 (1) ENGINE DOES NOT TURN..............................................................................................................................344 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)..........................................................................345 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..........................................................................346 S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR)..................................................................................................347 S-4 ENGINE STOPS DURING OPERATIONS........................................................................................................................348 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).............................................................................................................349 S-6 ENGINE LACKS OUTPUT...................................................................................................................................350 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)........................................................................................................351 S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...............................................................................................352 S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................................................353 S-10 FUEL CONSUMPTION IS EXCESSIVE........................................................................................................................354 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..............................................................................355 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...................................................................................................356 S-13 OIL LEVEL RISES......................................................................................................................................357 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....................................................................................................358 S-15 ABNORMAL NOISE IS MADE...............................................................................................................................359 S-16 VIBRATION IS EXCESSIVE...............................................................................................................................360 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE).........................................................................................................361 METHOD OF ERROR CODE DISPLAY..............................................................................................................................363 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED..........................................................................366 SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM...............................................................................................................374 EA- 1 ERROR CODE [111] (ABNORMALITY IN CONTROLLER MEMORY).................................................................................................376 EA- 2 ERROR CODE [112] (ABNORMALITY IN TIMING RAIL ACTUATOR...............................................................................................376 EA- 3 ERROR CODE [113] (ABNORMALITY WITH ELECTRIC CURRENT IN TIMING RAIL ACTUATOR SYSTEM).................................................................377 EA- 4 ERROR CODE [115] (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEM)......................................................................................378 EA- 5 ERROR CODE [116] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL).....................................................................380 EA- 6 ERROR CODE [117] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)......................................................................381 EA- 7 ERROR CODE [118] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM HIGH LEVEL).......................................................................382 EA- 8 ERROR CODE [119] (ABNORMALITY IN FUEL PUMP PRESSURE SENSOR SYSTEM LOW LEVEL)........................................................................383 EA- 9 ERROR CODE [121] (ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEM)......................................................................................384 EA-10 ERROR CODE [122] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM HIGH LEVEL)...........................................................................385 EA-11 ERROR CODE [123] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM LOW LEVEL)............................................................................386 EA-12 ERROR CODE [131] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM HIGH LEVEL)..............................................................................387 EA-13 ERROR CODE [132] (ABNORMALITY IN ACCELERATOR SENSOR SYSTEM LOW LEVEL)...............................................................................388 EA-14 ERROR CODE [135] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM HIGH LEVEL).............................................................................389 EA-15 ERROR CODE [141] (ABNORMALITY IN OIL PRESSURE SENSOR SYSTEM LOW LEVEL)..............................................................................390 EA-16 ERROR CODE [143] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 1))..........................................................................................391 EA-17 ERROR CODE [144] (ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM HIGH LEVEL)........................................................................392 EA-18 ERROR CODE [145] (ABNORMALITY IN WATER TEMPERATURE SENSOR SYSTEM LOW LEVEL).........................................................................393 EA-19 ERROR CODE [151] (ABNORMAL RISE IN WATER TEMPERATURE)...............................................................................................393 EA-20 ERROR CODE [153] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM HIGH LEVEL)...................................................................394 EA-21 ERROR CODE [154] (ABNORMALITY IN INTAKE AIR TEMPERATURE SENSOR SYSTEM LOW LEVEL)....................................................................394 EA-22 ERROR CODE [221] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM HIGH LEVEL).....................................................................395 EA-23 ERROR CODE [222] (ABNORMALITY IN ATMOSPHERIC PRESSURE SENSOR SYSTEM LOW )...........................................................................396 EA-24 ERROR CODE [234] (OVERSPEED)........................................................................................................................398 EA-25 ERROR CODE [254] (ABNORMALITY IN FUEL SHUT-OFF VALVE SYSTEM VOLTAGE)................................................................................399 EA-26 ERROR CODE [259] (ABNORMALITY IN FUEL SHUT-OFF VALVE)...............................................................................................400 EA-27 ERROR CODE [261] (ABNORMAL RISE IN FUEL TEMPERATURE)................................................................................................400 EA-28 ERROR CODE [263] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM HIGH LEVEL).........................................................................401 EA-29 ERROR CODE [265] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM LOW LEVEL)..........................................................................401 EA-30 ERROR CODE [316] (ABNORMALITY IN FUEL PUMP ACTUATOR SYSTEM CURRENT).................................................................................402 EA-31 ERROR CODE [318] (ABNORMALITY IN FUEL PUMP ACTUATOR)................................................................................................403 EA-32 ERROR CODE [343] (ABNORMALITY IN CONTROLLER INTERNAL COMMUNICATION).................................................................................403 EA-33 ERROR CODE [346] (ABNORMALITY IN CONTROLLER POWER DOWN).............................................................................................404 EA-34 ERROR CODE [384] (ABNORMALITY IN PREHEATING HEATER CONTROL SYSTEM)..................................................................................405 EA-35 ERROR CODE [415] (ABNORMAL DROP IN OIL PRESSURE (LEVEL 2))..........................................................................................406 EA-36 ERROR CODE [423] (ABNORMALITY IN TIMING RAIL PRESSURE SENSOR SYSTEM IN RANGE).......................................................................407 EA-37 ERROR CODE [431] (ABNORMALITY 1 IN IDLING VALIDATION SWITCH SYSTEM).................................................................................409 EA-38 ERROR CODE [432] (IDLING VALIDATION PROCESS ERROR)..................................................................................................411 EA-39 ERROR CODE [441] (ABNORMALITY IN BATTERY VOLTAGE LOW LEVEL).........................................................................................414 EA-40 ERROR CODE [442] (ABNORMALITY IN BATTERY VOLTAGE HIGH LEVEL)........................................................................................414 EA-41 ERROR CODE [451] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM HIGH LEVEL).......................................................................415 EA-42 ERROR CODE [452] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR SYSTEM LOW LEVEL)........................................................................416 EA-43 ERROR CODE [455] (ABNORMALITY IN FUEL RAIL ACTUATOR SYSTEM CURRENT).................................................................................417 EA-44 ERROR CODE [467] (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)......................................................................................418 EA-45 ERROR CODE [468] (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)........................................................................................418 EA-46 ERROR CODE [514] (ABNORMALITY IN FUEL RAIL ACTUATOR)................................................................................................418 EA-47 ERROR CODE [527] (ABNORMALITY IN DUAL OUTPUT SOLENOID A SYSTEM).....................................................................................419 EA-48 ERROR CODE [551] (ABNORMALITY 2 IN IDLING VALIDATION SWITCH SYSTEM).................................................................................419 EA-49 ERROR CODE [554] (ABNORMALITY IN FUEL RAIL PRESSURE SENSOR IN RANGE)................................................................................420 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...............................................................................................................423 ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR...............................................................................................................426 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN..............................................................................................................428 M- 1 MAIN MONITOR DOES NOT WORK...........................................................................................................................429 M- 2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP.......................................................430 M- 3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...........................................................................................................431 M- 4 ABNORMALITY IN SHIFT INDICATOR.......................................................................................................................432 a) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F.....................................................................................................432 b) DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R.....................................................................................................432 c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N.............................................................................................432 d) DOES NOT DISPLAY 1ST EVEN WHEN SPEED CONTROL LEVER IS AT 1ST.......................................................................................433 e) DOES NOT DISPLAY 2ND EVEN WHEN SPEED CONTROL LEVER IS AT 2ND.......................................................................................433 f) DOES NOT DISPLAY 3RD EVEN WHEN SPEED CONTROL LEVER IS AT 3RD.......................................................................................433 g) DOES NOT DISPLAY 4TH EVEN WHEN SPEED CONTROL LEVER IS AT 4TH.......................................................................................433 M- 5 HIGH BEAM DISPLAY DOES NOT LIGHT UP..................................................................................................................435 M- 6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP................................................................................................................436 a) LH TURN SIGNAL DISPLAY DOES NOT LIGHT UP...........................................................................................................436 b) RH TURN SIGNAL DISPLAY DOES NOT LIGHT UP...........................................................................................................436 M- 7 ABNORMALITY IN PARKING LAMP DISPLAY..................................................................................................................437 a) PARKING LAMP DISPLAY DOES NOT LIGHT UP.............................................................................................................437 b) PARKING LAMP DISPLAY STAYS LIGHTED UP..............................................................................................................437 M- 8 ABNORMALITY IN PREHEATING DISPLAY....................................................................................................................438 a) PREHEATING DISPLAY DOES NOT LIGHT UP...............................................................................................................438 b) PREHEATING DISPLAY STAYS LIGHTED UP................................................................................................................438 M- 9 NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP..........................................................................................................439 M-10 ABNORMALITY IN FRONT WORKING LAMP....................................................................................................................440 a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP............................................................................................440 b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.......................................................................................440 c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP.......................................................................................440 M-11 ABNORMALITY IN REAR WORKING LAMP.....................................................................................................................442 a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP.............................................................................................442 b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.......................................................................................442 c) MONITOR DISPLAY LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP.......................................................................................442 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF..................................................................................................................444 a) WHEN TRANSMISSION CUT-OFF SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE..........................................444 b) TRANSMISSION CUT-OFF DOES NOT WORK OR STAYS WORKING................................................................................................444 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING........................................................................................................445 a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS INTERMITTENTLY AND CAUTION LAMP FLASHES EVEN WHEN DIRECTIONAL LEVER IS AT N...........................445 b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N....445 M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED............................446 a) ACTUATED CONTINUOUSLY..............................................................................................................................446 b) NOT ACTUATED.......................................................................................................................................446 M-15 ABNORMALITY IN BUZZER................................................................................................................................447 a) BUZZER DOES NOT SOUND FOR 3 SECONDS DURING SELF-CHECK WHEN STARTING SWITCH IS TURNED ON............................................................447 b) BUZZER ALWAYS SOUNDS...............................................................................................................................447 M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY................................................................................................448 M-17 ABNORMALITY IN FAILURE DISPLAY MODE..................................................................................................................449 a) FAILURE DISPLAY MODE DOES NOT WORK.................................................................................................................449 b) COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY MODE DOES NOT ADVANCE......................................................................449 M-18 ABNORMALITY IN EMERGENCY STEERING DISPLAY............................................................................................................450 a) EMERGENCY STEERING DISPLAY DOES NOT FLASH..........................................................................................................450 b) EMERGENCY STEERING DISPLAY STAYS FLASHED...........................................................................................................450 M-19 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)....................................................................................451 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)........................................................................................................453 ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR........................................................................................................454 K- 1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS MAINTENANCE MONITOR DOES NOT WORK.................456 a) NO LAMPS ON MAINTENANCE MONITOR LIGHT UP...........................................................................................................456 b) SOME LAMPS DO NOT LIGHT UP.........................................................................................................................456 K- 2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT EVEN AFTER 3 SECONDS..................................457 K- 3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON WITHIN 3 SECONDS, NO LAMPS ON MAINTENANCE MONITOR GO OUT.......................458 K- 4 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TURNED ON, CHECK ITEM DISPLAY FLASHES..................................................................459 a) ENGINE OIL LEVEL DISPLAY FLASHES...................................................................................................................459 b) ENGINE WATER LEVEL DISPLAY FLASHES.................................................................................................................460 K- 5 WHEN ENGINE IS STOPPED AND STARTING SWITCH IS TURNED ON, CAUTION ITEM DISPLAY FLASHES................................................................461 a) ENGINE OIL PRESSURE DISPLAY FLASHES................................................................................................................461 b) BATTERY CHARGE DISPLAY FLASHES.....................................................................................................................462 c) BRAKE OIL PRESSURE DISPLAY FLASHES.................................................................................................................463 d) AIR CLEANER CLOGGED DISPLAY FLASHES................................................................................................................464 K- 6 CAUTION ITEM DISPLAY IS FLASHING, BUT CAUTION BUZZER DOES NOT SOUND..................................................................................465 K- 7 NO MONITOR DISPLAY LIGHTS UP, BUT CAUTION BUZZER SOUNDS..............................................................................................466 K- 8 CAUTION ITEM DISPLAY IS FLASHING, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP DOES NOT FLASH......................................................467 a) CHECK LAMP.........................................................................................................................................467 b) CAUTION LAMP.......................................................................................................................................467 K- 9 NO MAINTENANCE MONITOR DISPLAY LIGHTS UP, BUT CENTRAL CHECK LAMP OR CENTRAL CAUTION LAMP LIGHTS UP...................................................468 a) CHECK LAMP.........................................................................................................................................468 b) CAUTION LAMP.......................................................................................................................................468 K-10 ONLY NIGHT LIGHTING OF MONITOR DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON.......................................................................469 K-11 NIGHT LIGHTING OF MONITOR LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF.....................................................................................470 K-12 SERVICE METER DOES NOT WORK..........................................................................................................................471 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED.................................................................................................471 K-14 ABNORMALITY IN GAUGES................................................................................................................................472 a) ABNORMALITY IN FUEL GAUGE..........................................................................................................................472 b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE......................................................................................................473 c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE..............................................................................................474 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).................................................................................................................475 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING SYSTEM......................................................................477 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM................................................................................................478 ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE..............................................................................................................480 ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN..............................................................................................................481 E-1 ENGINE DOES NOT START.................................................................................................................................482 E-2 PREHEATING FAULT......................................................................................................................................488 E-3 PARKING BRAKE DOES NOT HAVE EFFECT....................................................................................................................489 a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON.................................................................................489 b) PARKING BRAKE HAS NO EFFECT AND DOES NOT WORK AS EMERGENCY BRAKE WHEN PARKING BRAKE PRESSURE DROPS.................................................489 E-4 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING....................................................................................................490 E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON...........................................................................................492 E-6 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED, BUT PARKING BRAKE WORKS NORMALLY...............................................492 E-7 TRANSMISSION DOES NOT WORK PROPERLY...................................................................................................................494 a) ABNORMALITY IN PARKING BRAKE CIRCUIT, TRANSMISSION CUT-OFF SWITCH CIRCUIT OR NEUTRALIZER RELAY CIRCUIT.............................................496 b) NO CONTINUITY IN TRAVEL FORWARD SOLENOID CIRCUIT...................................................................................................500 c) NO CONTINUITY IN TRAVEL REVERSE SOLENOID CIRCUIT...................................................................................................502 d) SHORT CIRCUIT TO CHASSIS GROUND IN DIRECTIONAL SOLENOID CIRCUIT....................................................................................504 e) ABNORMALITY IN SHIFT SOLENOID CIRCUIT..............................................................................................................510 f) AHORT CIRCUIT TO CHASSIS GROUND IN SHIFT SOLENOID CIRCUIT..........................................................................................515 E- 8 WHEN HOLD SWITCH IS PRESSED, GEAR SPEED IS NOT FIXED OR RESET GEAR SPEED IS NOT SHIFTED UP.........................................................520 E- 9 KICK-DOWN SYSTEM DOES NOT WORK GEAR SPEED IS NOT SHIFTED DOWN.......................................................................................520 E-10 POWER WINDOW DOES NOT WORK...........................................................................................................................521 a) POWER WINDOW DOES NOT RISE.........................................................................................................................521 b) POWER WINDOW DOES NOT LOWER........................................................................................................................522 E-11 ABNORMALITY IN FRONT WORKING LAMP....................................................................................................................524 E-12 ABNORMALITY IN REAR WORKING LAMP.....................................................................................................................524 E-13 ABNORMALITY IN TRANSMISSION CUT-OFF..................................................................................................................524 E-14 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING........................................................................................................524 E-15 ABNORMALITY IN BUZZER................................................................................................................................524 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...................................................................................................525 POWER TRAIN...............................................................................................................................................526 H- 1 MACHINE DOES NOT MOVE............................................................................................................................526 H- 2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS).................................................................................................527 H- 3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)..............................................................................................527 H- 4 MACHINE LACKS POWER OR SPEED WHEN TRAVELING......................................................................................................528 H- 5 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR........................................................................................530 H- 6 TORQUE CONVERTER OIL TEMPERATURE TOO HIGH........................................................................................................531 STEERING SYSTEM...........................................................................................................................................532 H- 7 STEERING WHEEL DOES NOT TURN.....................................................................................................................532 H- 8 STEERING DOES NOT TURN [MACHINE WITH JOYSTICK]...................................................................................................533 H- 9 TURNING, RESPONSE OF STEERING IS POOR............................................................................................................534 H-10 TURNING, RESPONSE OF STEERING IS POOR [MACHINE WITH JOYSTICK]....................................................................................536 H-11 STEERING IS HEAVY................................................................................................................................538 H-12 JOYSTICK IS HEAVY [MACHINE WITH JOYSTICK]........................................................................................................538 H-13 STEERING WHEEL SHAKES OR JERKS...................................................................................................................539 H-14 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK [MACHINE WITH JOYSTICK]..............................................................................540 H-15 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT MAXIMUM STEERING...........................................................................540 BRAKE SYSTEM..............................................................................................................................................542 H-16 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...............................................................................................542 H-17 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG.....................................................................................................544 H-18 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR............................................................................................545 H-19 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS.....................................................................................................546 WORK EQUIPMENT............................................................................................................................................547 H-20 BLADE DOES NOT RISE..............................................................................................................................547 H-21 BLADE MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER.....................................................................................548 H-22 BLADE BECOMES SLOW AT CERTAIN HEIGHT WHEN RAISING................................................................................................549 H-23 LIFT CYLINDER CANNOT HOLD DOWN BLADE.............................................................................................................549 H-24 BLADE HAS LARGE AMOUNT OF HYDRAULIC DRIFT........................................................................................................549 H-25 BLADE FLUCTUATES WHILE WORKING...................................................................................................................550 H-26 BLADE DROPS MOMENTARILY WHEN LEVER IS OPERATED FROM HOLD TO RAISE................................................................................550 H-27 BLADE DOES NOT TILT..............................................................................................................................551 H-28 BLADE MOVES SLOWLY OR HAS INSUFFICIENT TILT POWER................................................................................................552 H-29 BLADE DOES NOT PITCH.............................................................................................................................553 H-30 BLADE PITCH MOVEMENT IS SLOW OR LACKS POWER......................................................................................................553 H-31 WORK EQUIPMENT LEVER DOES NOT MOVE SMOOTHLY......................................................................................................554 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE).......................................................................................................555 METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE.........................................................................................................556 JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM...........................................................................................................557 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE...............................................................................558 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM................................................................................................562 T- 1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN LOCK-UP SOLENOID) IS DISPLAYED................................564 T- 2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN F SOLENOID) IS DISPLAYED......................................565 T- 3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN R SOLENOID) IS DISPLAYED......................................566 T- 4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 1ST SOLENOID) IS DISPLAYED....................................567 T- 5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 2ND SOLENOID) IS DISPLAYED....................................568 T- 6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 3RD SOLENOID) IS DISPLAYED....................................569 T- 7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN 4TH SOLENOID) IS DISPLAYED....................................570 T- 8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED..................................................571 T- 9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED...........................................................572 T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN SHIFT SWITCH SYSTEM) IS DISPLAYED.................................................................576 T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM) IS DISPLAYED.........................................................................579 T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED..........................................................580 T-13 WHEN HOLD SWITCH IS PRESSED, GEAR SPEED IS NOT FIXED OR RESET SHIFT UP DOES NOT WORK................................................................581 T-14 KICK-DOWN DOES NOT WORK SHIFT DOWN DOES NOT WORK....................................................................................................581 T-15 TRANSMISSION CUTOFF DOES NOT WORK OR STAYS WORKING...................................................................................................582 T-16 NEUTRALIZER DOES NOT WORK OR STAYS WORKING...........................................................................................................583 T-17 BUZZER DOES NOT WORK.................................................................................................................................584 T-18 ABNORMALITY IN NETWORK SYSTEM........................................................................................................................585 T-19 ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY..................................................................................................586 T-20 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM..........................................................................................................587 T-21 ABNORMALITY IN MACHINE SELECTION WIRING HARNESS......................................................................................................588 TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE)..........................................................................................................589 JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM...............................................................................................................590 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE................................................................................592 ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM...................................................................................................596 J- 1 FAILURE CODE [56] (SHORT CIRCUIT, OR DISCONNECTION IN CAUTION RELAY OUTPUT) IS DISPLAYED.............................................................598 J- 2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED ........................................599 J- 3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN SIGNAL IS OUTPUT)) IS DISPLAYED ..........................................600 J- 4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED ......................................................601 J- 5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (POWER SUPPLY SIDE)) IS DISPLAYED .......................................................602 J- 6 FAILURE CODE [61] (SHORT CIRCUIT, OR DISCONNECTION IN STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED...............................................603 J- 7 FAILURE CODE [62] (SHORT CIRCUIT, OR DISCONNECTION IN JOYSTICK STEERING NEUTRAL CIRCUIT) IS DISPLAYED................................................604 J- 8 FAILURE CODE [63] (SHORT CIRCUIT, OR DISCONNECTION IN JOYSTICK STEERING POTENTIOMETER) IS DISPLAYED..................................................605 J- 9 ABNORMALITY IN POWER SUPPLY, OR POWER SUPPLY VOLTAGE.................................................................................................606 J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF CIRCUIT......................................................................................................607 J-11 DISCONNECTION IN STEERING RIGHT SOLENOID.............................................................................................................608 J-12 DISCONNECTION IN STEERING LEFT SOLENOID..............................................................................................................609 TROUBLESHOOTING OF THROTTLE CONTROL SYSTEM (TH MODE)..........................................................................................................611 JUDGEMENT TABLE FOR THROTTLE CONTROLLER SYSTEM RELATED PARTS..............................................................................................613 ELECTRIC CIRCUIT DIAGRAM OF THROTTLE CONTROLLER SYSTEM....................................................................................................614 TH-1 ABNORMALITY IN ACCELERATOR PEDAL SENSOR SYSTEM IS DISPLAYED..........................................................................................615 TH-2 SHORT CIRCUIT IN RPM-SET IDLE-UP/RESUME IDLE-DOWN SWITCH SYSTEM IS DISPLAYED.........................................................................616 TH-3 DISCONNETION IN RPM-SET IDLE-UP/RESUME IDLE-DOWN SWITCH SYSTEM.......................................................................................617 TH-4 ABNORMALITY IN ELECTRONIC GOVERNOR VOLTAGE COMMAND SYSTEM............................................................................................618 TH-5 ABNORMALITY IN BRAKE PEDAL SWITCH SYSTEM.............................................................................................................619 a) ABNORMALITY IN LEFT BRAKE PEDAL SWITCH.............................................................................................................619 b) ABNORMALITY IN RIGHT BRAKE PEDAL SWITCH............................................................................................................620 TH-6 ABNORMALITY IN RPM-SET ON/OFF SWITCH SYSTEM..........................................................................................................621 TH-7 SHORT CIRCUIT, DISCONNECTION, OR SHORT CIRCUIT WITH POWER SUPPLY IN BACKUP LAMP RELAY................................................................622 30 DISASSEMBLY AND ASSEMBLY...........................................................................................................................................623 METHOD OF USING MANUAL............................................................................................................................................625 PRECAUTIONS WHEN CARRYING OUT OPERATION...........................................................................................................................626 SPECIAL TOOL LIST.................................................................................................................................................628 SKETCHES OF SPECIAL TOOLS.........................................................................................................................................632 STARTING MOTOR....................................................................................................................................................636 REMOVAL AND INSTALLATION......................................................................................................................................636 ALTERNATOR........................................................................................................................................................637 REMOVAL AND INSTALLATION......................................................................................................................................637 RADIATOR..........................................................................................................................................................638 REMOVAL.......................................................................................................................................................638 INSTALLATION..................................................................................................................................................640 ENGINE AND TORQUE CONVERTER ASSEMBLY..............................................................................................................................641 REMOVAL.......................................................................................................................................................641 INSTALLATION..................................................................................................................................................644 TORQUE CONVERTER..................................................................................................................................................645 REMOVAL.......................................................................................................................................................645 INSTALLATION..................................................................................................................................................646 DISASSEMBLY...................................................................................................................................................647 ASSEMBLY......................................................................................................................................................653 TRANSMISSION......................................................................................................................................................660 REMOVAL.......................................................................................................................................................660 INSTALLATION..................................................................................................................................................662 DISASSEMBLY...................................................................................................................................................663 ASSEMBLY......................................................................................................................................................678 TRANSMISSION VALVE................................................................................................................................................694 REMOVAL AND INSTALLATION......................................................................................................................................694 TRANSFER..........................................................................................................................................................695 DISASSEMBLY...................................................................................................................................................695 ASSEMBLY......................................................................................................................................................704 CENTER SUPPORT....................................................................................................................................................714 REMOVAL AND INSTALLATION......................................................................................................................................714 DISASSEMBLY...................................................................................................................................................716 ASSEMBLY......................................................................................................................................................718 DRIVE SHAFT.......................................................................................................................................................721 DISASSEMBLY...................................................................................................................................................721 ASSEMBLY......................................................................................................................................................724 FRONT AXLE........................................................................................................................................................727 REMOVAL.......................................................................................................................................................727 INSTALLATION..................................................................................................................................................728 FRONT DIFFERENTIAL................................................................................................................................................729 REMOVAL.......................................................................................................................................................729 INSTALLATION..................................................................................................................................................730 REAR AXLE.........................................................................................................................................................731 REMOVAL.......................................................................................................................................................731 INSTALLATION..................................................................................................................................................734 REAR DIFFERENTIAL.................................................................................................................................................735 REMOVAL.......................................................................................................................................................735 INSTALLATION..................................................................................................................................................736 DIFFERENTIAL GEAR.................................................................................................................................................737 DISASSEMBLY...................................................................................................................................................737 ASSEMBLY......................................................................................................................................................741 FINAL DRIVE.......................................................................................................................................................749 DISASSEMBLY...................................................................................................................................................749 ASSEMBLY......................................................................................................................................................753 ORBITROL..........................................................................................................................................................758 REMOVAL AND INSTALLATION......................................................................................................................................758 STEERING CYLINDER.................................................................................................................................................759 REMOVAL.......................................................................................................................................................759 INSTALLATION..................................................................................................................................................760 STEERING VALVE....................................................................................................................................................761 REMOVAL.......................................................................................................................................................761 INSTALLATION..................................................................................................................................................762 BRAKE VALVE.......................................................................................................................................................763 REMOVAL AND INSTALLATION......................................................................................................................................763 BRAKEVALVE (R.H.).................................................................................................................................................764 DISASSEMBLY...................................................................................................................................................764 ASSEMBLY......................................................................................................................................................766 BRAKEVALVE (L.H.).................................................................................................................................................768 DISASSEMBLY...................................................................................................................................................768 ASSEMBLY......................................................................................................................................................770 SLACK ADJUSTER....................................................................................................................................................772 REMOVAL AND INSTALLATION......................................................................................................................................772 DISASSEMBLY...................................................................................................................................................773 ASSEMBLY......................................................................................................................................................774 BRAKE.............................................................................................................................................................775 REMOVAL AND INSTALLATION......................................................................................................................................775 DISASSEMBLY...................................................................................................................................................776 ASSEMBLY......................................................................................................................................................779 HYDRAULIC PUMP....................................................................................................................................................783 REMOVAL.......................................................................................................................................................783 INSTALLATION..................................................................................................................................................784 HYDRAULIC TANK....................................................................................................................................................785 REMOVAL.......................................................................................................................................................785 INSTALLATION..................................................................................................................................................786 HYDRAULIC FILTER..................................................................................................................................................787 REMOVAL AND INSTALLATION......................................................................................................................................787 PPC VALVE.........................................................................................................................................................788 REMOVAL AND INSTALLATION......................................................................................................................................788 DISASSEMBLY AND ASSEMBLY......................................................................................................................................789 DECO VALVE........................................................................................................................................................790 REMOVAL AND INSTALLATION......................................................................................................................................790 WORK EQUIPMENT VALVE..............................................................................................................................................791 REMOVAL.......................................................................................................................................................791 INSTALLATION..................................................................................................................................................792 PITCH & TILT CYLINDER.............................................................................................................................................793 REMOVAL AND INSTALLATION......................................................................................................................................793 LIFT CYLINDER.....................................................................................................................................................794 REMOVAL.......................................................................................................................................................794 INSTALLATION..................................................................................................................................................795 CENTER HINGE PIN..................................................................................................................................................796 REMOVAL.......................................................................................................................................................796 INSTALLATION..................................................................................................................................................801 WORK EQUIPMENT....................................................................................................................................................804 REMOVAL.......................................................................................................................................................804 INSTALLATION..................................................................................................................................................807 BULKHEAD..........................................................................................................................................................808 REMOVAL.......................................................................................................................................................808 INSTALLATION..................................................................................................................................................809 FLOOR FRAME.......................................................................................................................................................810 REMOVAL.......................................................................................................................................................810 INSTALLATION..................................................................................................................................................812 COUNTERWEIGHT.....................................................................................................................................................813 REMOVAL AND INSTALLATION......................................................................................................................................813 FUEL TANK.........................................................................................................................................................814 REMOVAL.......................................................................................................................................................814 INSTALLATION..................................................................................................................................................815 CAB...............................................................................................................................................................816 REMOVAL.......................................................................................................................................................816 INSTALLATION..................................................................................................................................................818 STOP VALVE........................................................................................................................................................819 REMOVAL AND INSTALLATION......................................................................................................................................819 ACCUMULATOR.......................................................................................................................................................820 REMOVAL.......................................................................................................................................................820 INSTALLATION..................................................................................................................................................821 ACCUMULATOR CHARGE VALVE..........................................................................................................................................823 REMOVAL AND INSTALLATION......................................................................................................................................823 PARKING BRAKE SOLENOID VALVE......................................................................................................................................824 REMOVAL AND INSTALLATION......................................................................................................................................824 DIVERTER VALVE....................................................................................................................................................825 REMOVAL AND INSTALLATION......................................................................................................................................825 EMERGENCY STEERING PUMP...........................................................................................................................................826 REMOVAL AND INSTALLATION......................................................................................................................................826 PARKING BRAKE.....................................................................................................................................................827 REMOVAL.......................................................................................................................................................827 INSTALLATION..................................................................................................................................................828 PARKING BRAKE CALIPERS............................................................................................................................................830 DISASSEMBLY...................................................................................................................................................830 ASSEMBLY......................................................................................................................................................831 PARKING BRAKE PAD.................................................................................................................................................832 REMOVAL AND INSTALLATION......................................................................................................................................832 REAR TIRES........................................................................................................................................................833 REMOVAL AND INSTALLATION......................................................................................................................................833 AIR CONDITIONER COMPRESSOR........................................................................................................................................834 REMOVAL AND INSTALLATION......................................................................................................................................834 AIR CONDITIONER CONDENSER.........................................................................................................................................835 REMOVAL AND INSTALLATION......................................................................................................................................835 RECEIVER TANK.....................................................................................................................................................836 REMOVAL AND INSTALLATION......................................................................................................................................836 AIR CONDITIONER UNIT..............................................................................................................................................837 REMOVAL.......................................................................................................................................................837 INSTALLATION..................................................................................................................................................838 MONITOR...........................................................................................................................................................839 REMOVAL AND INSTALLATION......................................................................................................................................839 40 MAINTENANCE STANDARD...............................................................................................................................................841 ENGINE MOUNT......................................................................................................................................................842 TRANSMISSION MOUNT................................................................................................................................................843 TORQUE CONVERTER..................................................................................................................................................844 LOCK-UP VALVE.....................................................................................................................................................846 TORQUE CONVERTER REGULATOR VALVE..................................................................................................................................847 TRANSMISSION......................................................................................................................................................848 TRANSMISSION SOLENOID VALVE.......................................................................................................................................851 TRANSMISSION CONTROL VALVE........................................................................................................................................852 TRANSFER..........................................................................................................................................................856 DRIVE SHAFT.......................................................................................................................................................858 CENTER SUPPORT....................................................................................................................................................859 DIFFERENTIAL......................................................................................................................................................860 NON-SPIN DIFFERENTIAL.............................................................................................................................................864 FINAL DRIVE.......................................................................................................................................................866 AXLE MOUNT........................................................................................................................................................868 CENTER HINGE PIN..................................................................................................................................................870 STEERING COLUMN...................................................................................................................................................872 STEERING VALVE....................................................................................................................................................873 EMERGENCY STEERING PUMP...........................................................................................................................................874 DIVERTER VALVE....................................................................................................................................................875 STEERING CYLINDER MOUNT...........................................................................................................................................876 BRAKE VALVE.......................................................................................................................................................877 SLACK ADJUSTER....................................................................................................................................................880 BRAKE.............................................................................................................................................................881 PARKING BRAKE.....................................................................................................................................................882 HYDRAULIC PUMP....................................................................................................................................................883 PPC VALVE.........................................................................................................................................................886 WORK EQUIPMENT VALVE..............................................................................................................................................888 HYDRAULIC CYLINDER................................................................................................................................................890 WORK EQUIPMENT LINKAGE............................................................................................................................................894 BLADE.............................................................................................................................................................898 ROPS CANOPY.......................................................................................................................................................899 90 OTHERS.............................................................................................................................................................901 BRAKE CIRCUIT DIAGRAM.............................................................................................................................................902 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.........................................................................................................................905 HYDRAULIC CIRCUIT DIAGRAM.........................................................................................................................................907 ELECTRIC CIRCUIT DIAGRAM (1/8)....................................................................................................................................911 ELECTRIC CIRCUIT DIAGRAM (2/8)....................................................................................................................................913 ELECTRIC CIRCUIT DIAGRAM (3/8)....................................................................................................................................915 ELECTRIC CIRCUIT DIAGRAM (4/8)....................................................................................................................................917 ELECTRIC CIRCUIT DIAGRAM (5/8)....................................................................................................................................919 ELECTRIC CIRCUIT DIAGRAM (6/8)....................................................................................................................................921 ELECTRIC CIRCUIT DIAGRAM (7/8)....................................................................................................................................923 ELECTRIC CIRCUIT DIAGRAM (8/8)....................................................................................................................................925 ELECTRIC CIRCUIT DIAGRAM (FOR BATTERY DISCONNECT SWITCH CIRCUIT)..................................................................................................927
DESCRIPTION:
KOMATSU WD600-3 SHOP MANUAL SEBM022908 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 22/12/24
